WO2023216108A1

WO2023216108A1 - Fuel tank assembly with integrated filter housing

Info

Publication number: WO2023216108A1
Application number: PCT/CN2022/091997
Authority: WO
Inventors: Changwei Wang; Chunxi WANG; Yiyun Zhang
Original assignee: Cummins Filtration Inc.
Priority date: 2022-05-10
Filing date: 2022-05-10
Publication date: 2023-11-16

Abstract

A fuel tank assembly (200) includes a tank shell (202), a filter shell (206), and a filter assembly (300).The tank shell (202) defines a fluid reservoir (204).The filter shell (206) defines an interior cavity (218). The filter shell (206 )extends into the fluid reservoir (204) and separates the fluid reservoir (204) from the interior cavity (218). The filter assembly (300) is coupled to the tank shell (202) and extends into the interior cavity (218). In some embodiments, the fuel tank assembly (200) further includes a fuel pump (308) coupled to the filter assembly (300) and extending into the interior cavity (218).

Description

FUEL TANK ASSEMBLY WITH INTEGRATED FILTER HOUSING

TECHNICAL FIELD

The present disclosure relates generally to filters for use with internal combustion engine systems.

BACKGROUND

Internal combustion engine systems require fuel (e.g., diesel fuel, gasoline, etc. ) to operate. The fuel may be contaminated with water and/or particulate matter, which may damage various parts of the engine system if not removed from the fluid. To remove water and other contaminants, the fuel is generally passed through a filter assembly, which may include a particulate filter and/or fuel-water separator.

SUMMARY

One embodiment of the present disclosure relates to a fuel tank assembly. The fuel tank assembly includes a tank shell, a filter shell, and a filter assembly. The tank shell defines a fluid reservoir. The filter shell defines an interior cavity. The filter shell extends into the fluid reservoir and separates the fluid reservoir from the interior cavity. The filter assembly is coupled to the tank shell and extends into the interior cavity.

Another embodiment of the present disclosure relates to a fuel tank. The fuel tan includes a tank shell and a filter shell. The tank shell includes a tank lower wall, a tank upper wall, and at least one tank side wall. The tank lower wall, the tank upper wall, and the at least one tank side wall together define a fluid reservoir. The filter shell is integrally formed with at least one of the tank upper wall or the tank lower wall from a single piece of material. The filter shell extends into the fluid reservoir between the tank upper wall and the tank lower wall. The filter shell defines an interior cavity that is accessible from a first tank opening in at least one of the tank upper wall or the tank lower wall.

Still another embodiment of the present disclosure relates to a filter element comprising a media block circumscribing a central cavity, a first end plate, and a second end plate. The first end plate is coupled to a first axial end of the media block. The first end plate includes a first end plate base and a first end plate ledge extending radially away from the first end plate base. The first end plate ledge is configured to engage a ledge of a filter shell along an axial direction. The first end plate has a first outer diameter. The second end plate is coupled to a second axial end of the media block. The second end plate includes a second end plate sealing element facing radially away from a central axis of the central cavity. The second end plate has a second outer diameter that is less than the first outer diameter of the first end plate.

BRIEF DESCRIPTION OF THE FIGURES

The foregoing and other features of the present disclosure will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only several implementations in accordance with the disclosure and are therefore, not to be considered limiting of its scope, the disclosure will be described with additional specificity and detail through use of the accompanying drawings.

FIG. 1 is a side cross-sectional view of a fuel tank assembly, according to an embodiment.

FIG. 2 is another side cross-sectional view of a filter assembly portion of the fuel tank assembly of FIG. 1.

FIG. 3 is a top perspective view of a tank shell of the fuel tank assembly of FIG. 1.

FIG. 4 is a side cross-sectional view of the tank shell of FIG. 3.

FIG. 5 is another side cross-sectional view of the tank shell of FIG. 3.

FIG. 6 is a side cross-sectional view of the filter tank assembly of FIG. 1 in an area near a shell conduit.

FIG. 7 is a side cross-sectional view of an upper portion of a filter assembly of the fuel tank assembly of FIG. 1.

FIG. 8 is a side cross-sectional view of a lower portion of a filter assembly of FIG. 7.

FIG. 9 is a side cross-sectional view of a filter assembly portion of the fuel tank assembly of FIG. 1.

Reference is made to the accompanying drawings throughout the following detailed description. In the drawings, similar symbols typically identify similar components, unless context dictates otherwise. The illustrative implementations described in the detailed description, drawings, and claims are not meant to be limiting. Other implementations may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented here. It will be readily understood that the aspects of the present disclosure, as generally described herein, and illustrated in the figures, can be arranged, substituted, combined, and designed in a wide variety of different configurations, all of which are explicitly contemplated and made part of this disclosure.

DETAILED DESCRIPTION

Embodiments described herein relate generally to fuel filtration systems. The various concepts introduced above and discussed in greater detail below may be implemented in any of numerous ways, as the described concepts are not limited to any particular manner of implementation. Examples of specific implementations and applications are provided primarily for illustrative purposes.

I. Overview

Internal combustion engine systems require a clean source of fluids (e.g., fuel, oil, etc. ) to power and lubricate the engine. Unfiltered fluids may include dirt, metal particles, and other solid contaminants that can damage engine components (e.g., fuel injectors, cylinder rings, pistons, etc. ) . In order to protect the engine components, the internal combustion engine systems may include a filtration system, which filters incoming and/or recirculating fluids to remove any solid materials before passing the fluids to the engine. In some instances, the filtration system includes a filter housing and a replaceable filter cartridge, which may be periodically replaced by an operator and/or technician to maintain the differential pressure across the filtration system to within reasonable levels.

Referring to the figures generally, a fuel filtration system for an internal combustion engine system is shown. The fuel filtration system filters dirty fuel received from a fuel tank (e.g., tank shell, etc. ) and provides clean, filtered fuel to the engine system. In contrast to existing fuel filtration systems, embodiments of the fuel filtration system include a filter shell that is integrated into the fuel tank and forms part of the fuel tank. In at least one embodiment, the filter shell is integrally formed with the fuel tank as a unitary structure from a single piece of material. The filter shell defines an interior cavity of the filter assembly and separates the interior cavity from a fluid reservoir of the fuel tank. The filter shell may also include a fuel inlet port that fluidly couples the fuel tank to the filter shell. The fuel inlet port may be positioned to automatically deliver fuel to the internal cavity based on a level of fuel within the fluid reservoir, which can prevent fuel starvation to the fuel filtration system at engine shutdown (when the fuel pump is not operating) . Beneficially, integrating the filter shell with the fuel tank reduces the number of mounting points required onboard a vehicle, and reduces the packaging space needed to accommodate the fuel filtration system.

In some embodiments, the fuel filtration system includes a filter assembly. The filter assembly may include a replaceable filter element that is received in the interior cavity through an opening along an upper wall of the fuel tank. The filter element sealingly engages with the filter shell to separate clean and dirty fuel. In some embodiments, the filter assembly is structured to threadably engage the fuel tank at the opening. In some implementations, venting for the fuel tank can be integrated into the filter assembly (e.g., filter head, etc. ) . For example, the filter assembly may include a vent port that can be used to vent both the filter shell and the fuel tank.

In at least one embodiment, a fuel pump for the fuel filtration system is integrated into the filter assembly. For example, the filter assembly may include a filter element defining a central cavity and a fuel pump extending into the central cavity. Beneficially, integrating the fuel pump into the filter assembly can further reduce the overall packaging space needed to accommodate the fuel filtration system onboard a vehicle.

In at least one embodiment, the fuel filtration system integrates a fuel-water separator system of the filter assembly into the fuel tank. In some embodiments, the filter shell extends between the upper wall of the fuel tank and a lower wall of the fuel tank. The fuel tank may further include a drain port disposed in the lower wall at a lower end of the filter shell. In some embodiments, the drain port is a single drain for the fuel system that is structured to drain water from both the fuel tank and the filter shell. The fuel filtration system may also include a water-in-fuel sensor coupled to the lower wall of the fuel tank and configured to detect the presence of water within the fuel tank. Among other benefits, integrating the filter shell into the fuel tank can eliminate the need for a separate drain valve in both the fuel tank and the filter assembly.

II. Example Fuel Filtration System

FIGS. 1–2 show fluid filtration system, shown as filtration system 100, according to an embodiment. The filtration system 100 may be used to filter a fluid provided to an internal combustion engine to remove contaminants, particulate matter, and/or water from the fluid. The fluid may be a fuel, an engine oil, a hydraulic oil, or another fluid or lubricant. In the example embodiment of FIGS. 1–2, the filtration system 100 is a fuel filtration system for a diesel engine that uses diesel fuel to drive the combustion process.

In the embodiment of FIGS. 1–2, the filtration system 100 includes a fuel tank assembly 200 and a filter assembly 300 that is received within the fuel tank assembly 200. As shown in FIGS. 1–2, the fuel tank assembly 200 includes a tank shell 202 defining a fluid reservoir 204. The fluid reservoir 204 is structured to contain a volume of fluid (e.g., fuel, etc. ) . At least one component (e.g., element, etc. ) of the filtration system 100 is integrally formed with the tank shell 202. In the embodiment of FIGS. 1–2, a filter shell 206 of the filtration system 100 is integrally formed with the tank shell 202 from a single piece of material.

FIGS. 3–5 show the tank shell 202 of the fuel tank assembly 200 of FIGS. 1–2. As shown in FIGS. 3–5, the tank shell 202 includes a tank upper wall 208, a tank lower wall 210, and at least one tank side wall 212. The tank upper wall 208, the tank lower wall 210, and the at least one tank side wall 212 together define the fluid reservoir 204. In the embodiment of FIGS. 3–5, the tank shell 202 includes a plurality of tank side walls so that the tank shell 202 is in the shape of a rectangular prism (e.g., cube, etc. ) . In other embodiments, the shape of the tank shell 202 may be different. For example, the tank shell 202 may be substantially cylindrical or any other suitable shape.

In at least one embodiment, the fuel tank assembly 200 also includes a filter shell 206. In the embodiment of FIGS. 3–5, the filter shell 206 is integrally formed with the tank shell 202 from a single piece of material. As such, the filter shell 206 may be considered as part of the tank shell 202.

As user herein, “integrally formed” refers to the joining of two components as a unitary body that cannot be separated or disconnected without damaging or destroying the component (s) . In the embodiment shown, the filter shell 206 and tank shell 202 are formed together from a plastic material using a blow-molding or a rotational molding operation so that there are no seams between the filter shell 206 and the tank shell 202. The filter shell 206 and the tank shell 202 may be made from a polyethylene material or another suitably strong and fuel-compatible material that does not degrade or break down when exposed to fuel. In other embodiments, the filter shell 206 and/or tank shell 202 may include metal such as steel or aluminum.

Although the tank shell 202 and the filter shell 206 are shown as being formed from a single continuous piece, it should be appreciated that the filter shell 206 could be formed separately from the tank shell 202 in other embodiments. For example, the filter shell 206 could be formed from a separate piece of plastic or metal that is inserted into the tank shell 202 and sealingly engaged with the tank shell 202 (e.g., at an upper axial end of the filter shell 206 and/or an opposing lower axial end of the filter shell 206, etc. ) . The filter shell 206 may be attached to the tank shell 202 via an ultrasonic welding operation, a spin welding operation, or via another suitable joining process. In other embodiments, the filter shell 206 is threadably engaged with the tank shell 202 (e.g., to the tank upper wall 208, the tank lower wall 210, etc. ) and includes sealing members (e.g., O-rings, gaskets, etc. ) to prevent fuel from leaking through the connection between the filter shell 206 and the tank shell 202.

As shown in FIGS. 3–4, the filter shell 206 is disposed at a central position within the tank shell 202. The filter shell 206 is coupled to the tank upper wall 208 at a central position along the tank upper wall 208 (e.g., disposed approximately equidistant from opposing tank side walls of the tank shell 202) . In some embodiments, the tank shell 202 includes a recessed area 214 (e.g., depression, etc. ) disposed at the central position along the tank upper wall 208. In other embodiments, the tank upper wall 208 is substantially planar or continuous along its entire surface surrounding the filter shell 206.

As shown in FIG. 2, the filter assembly 300 is coupled to the tank shell 202 and includes a filter element 302 that extends into the filter shell 206. In at least one embodiment-as shown in FIG. 2-the filter assembly 300 is threadably engaged with the tank shell 202.

In the embodiment of FIG. 2, the tank shell 202 includes an opening, shown as first tank opening 216, disposed in the tank upper wall 208 providing access into the filter shell 206. The first tank opening 216 provides access into an interior cavity 218 of the filter shell 206, as will be further described. The tank shell 202 also includes a cylindrical protrusion 220 extending outwardly from the tank shell 202 (e.g., the tank upper wall 208 and away from the fluid reservoir 204) in a substantially perpendicular orientation relative to the tank upper wall 208.

As shown in FIGS. 3–4, the cylindrical protrusion 220 of the tank shell 202 includes a threaded interface 222 extending along an outer surface of the cylindrical protrusion 220. In other embodiments, the cylindrical protrusion 220 includes a twist-lock interface and/or another suitable coupler to secure the filter assembly 300 to the tank shell 202 (see FIG. 2) . In some embodiments, the recessed area circumscribes (e.g., surrounds, etc. ) the cylindrical protrusion 220.

In at least one embodiment, as shown in FIG. 5, a height 224 of the cylindrical protrusion 220 is less than a depth 226 of the recessed area 214. Among other benefits, positioning the cylindrical protrusion 220 (e.g., the connection for the filter assembly) within the recessed area 214 and below the tank upper wall 208 can ensure that the filter assembly 300 does not protrude beyond the tank upper wall 208 when installed into the tank shell 202. In other embodiments, tank upper wall 208 does not include a recessed area 214. In yet other embodiments, the tank shell 202 includes a threaded connection or another suitable coupler at another location along the tank shell 202 and/or filter shell 206.

In at least one embodiment, the filter shell 206 is coupled to at least one of the tank upper wall 208 or the tank lower wall 210 (e.g., the tank upper wall 208, the tank lower wall 210, or a combination of the tank upper wall 208 and the tank lower wall 210) and extends into the fluid reservoir 204 between the tank upper wall 208 and the tank lower wall 210. As shown in FIGS. 4–5, the filter shell 206 is engaged with and extends between the tank upper wall 208 and the tank lower wall 210. In the embodiment of FIGS. 4–5, the filter shell 206 comprises a cylindrical extension that extends away from the tank upper wall 208 in a substantially perpendicular orientation relative to the tank upper wall 208.

As shown in FIG. 2, the filter shell 206 is structured to seal against the filter assembly 300 to prevent bypass across the filter assembly 300 (e.g., between the clean and dirty sides of the filter element 302) .

As shown in FIG. 5, the filter shell 206 includes multiple wall sections, including a first filter shell wall 228, a second filter shell wall 230 (e.g., an upper axial wall) , a third filter shell wall 232, and a fourth filter shell wall 234 (e.g., a lower axial wall) . The first filter shell wall 228 is engaged with and extends radially away from the first tank opening 216 and toward a central axis 236 of the filter shell 206. Together, the first filter shell wall 228 and the cylindrical protrusion 220 form a substantially L-shaped upper ledge, shown as upper filter shell ledge 238, that extends along a circumferential direction just below an upper end of the cylindrical protrusion 220.

As shown in FIG. 2, the upper filter shell ledge 238 is structured to engage with an end plate of the filter assembly 300 to prevent over-insertion of the filter element 302 into the filter shell 206. A lower end of the filter shell 206 is structured to sealingly engage the filter assembly 300 (e.g., a lower end plate of the filter element 302) to prevent fluid bypass between the clean and dirty sides of the filter element 302.

As shown in FIG. 5, the second filter shell wall 230 (e.g., the upper axial wall) is engaged with an inner edge of the first filter shell wall 228. The second filter shell wall 230 extends axially away from the first filter shell wall 228 (and the tank upper wall 208) and into the fluid reservoir 204. The third filter shell wall 232 is engaged with and extends radially away from the second filter shell wall 230 and toward the central axis 236 of the filter shell 206 to form a substantially L-shaped lower ledge, shown as lower filter shell ledge 240. Beneficially, the change in the diameter of the filter shell 206, across the lower filter shell ledge 240, reduces the force required to insert the filter assembly 300 into the filter shell 206 (as a result of the difference in diameter between the lower end plate of the filter element and the second filter shell wall 230) .

As shown in FIG. 2, the fourth filter shell wall 234 is structured to sealingly engage the filter element 302 at a lower end plate of the filter element 302. As shown in FIG. 5, the fourth filter shell wall 234 comprises a lower cylindrical extension that extends axially between the second filter shell wall 230 and the tank lower wall 210. In particular, the fourth filter shell wall 234 is engaged with and extends axially between both an inner edge of the third filter shell wall 232 and the tank lower wall 210. In some embodiments, the fourth filter shell wall 234 and the tank lower wall 210 together form a water collection bowl of the filter shell 206.

As shown in FIG. 5, the fourth filter shell wall 234 has a first inner diameter 237 that is less than a second inner diameter 239 of the second filter shell wall 230 which, beneficially, facilitates engagement with and sealing between the filter element 302 (at the lower end plate of the filter element 302) and the filter shell 206. In at least one embodiment, the lower filter shell ledge 240 has tapered and/or rounded corners to facilitate alignment (centering) between the filter element 302 and the filter shell 206 during installation. In yet other embodiments, the lower filter shell ledge 240 is angled toward the tank lower wall 210.

Returning to FIG. 2, the filter shell 206 is structured to fluidly couple the interior cavity 218 to the fluid reservoir 204 of the tank shell 202. In the embodiment of FIG. 5, the filter shell 206 includes a shell conduit 254 that fluidly couples the fluid reservoir 204 to the interior cavity 218. The shell conduit 254 extends from an outer side wall of the filter shell 206 (e.g., third filter shell wall 232) axially toward the tank lower wall 210 of the filter shell 206. An inlet 256 of the shell conduit 254 is disposed proximate the tank lower wall 210. An outlet 258 of the shell conduit 260 is disposed in the third filter shell wall 232 (e.g., the lower filter shell ledge 240) . In other embodiments, the position of the shell conduit 254 may be different. Beneficially, the location of the shell conduit 254 helps ensure a uniform fuel height between the fluid reservoir 204 and the interior cavity 218 and allows fuel to enter the interior cavity 218 even when the fuel pump is shut off (e.g., due to the difference in hydrostatic pressure between the fuel in the tank shell 202 and the interior cavity 218) .

In at least one embodiment, the fuel tank assembly 200 further includes a flow control valve to prevent back flow of dirty fuel from the interior cavity 218 to the fluid reservoir 204. For example, as shown in FIG. 6, the fuel tank assembly 200 includes a check valve 257 coupled to the shell conduit 254 proximate to the outlet 258 of the shell conduit 254. The check valve 257 may be at least partially disposed within the shell conduit 254. The check valve 257 may be engaged with a step (e.g., ledge, counterbore, etc. ) within the shell conduit 254. In the embodiment of FIG. 6, the check valve 257 is a one-way check valve that is structured to prevent back flow of fuel from the interior cavity 218 to the fluid reservoir 204 (e.g., to maintain an approximately constant amount of fuel within the interior cavity 218 even when the fuel pump is shut off) .

Returning to FIG. 2, a drain valve 242 for the filter assembly 300 is integrated into the tank shell 202, and is structured to drain or otherwise facilitate removal of water from both the filter shell 206 and the tank shell 202. As shown in FIG. 5, the tank shell 202 includes a second tank opening 244 disposed in the tank lower wall 210. The second tank opening 244 is disposed at a lower end of the interior cavity 218 and is directly fluidly coupled to the interior cavity 218. As shown in FIG. 2, the drain valve 242 is coupled to the tank lower wall 210 via the second tank opening 244.

In some embodiments, the filtration system 100 also includes a water-in-fuel (WIF) sensor configured to detect the presence of water within the interior cavity 218 and/or fluid reservoir 204. In the embodiment of FIG. 2, the filtration system 100 includes a WIF sensor 246 coupled to the tank lower wall 210 of the tank shell 202 adjacent to the drain valve 242. The WIF sensor 246 is coupled to a third tank opening 248 in the tank lower wall 210 at a lower end of the interior cavity 218.

In some embodiments, the WIF sensor 246 is configured to transmit a notification to indicate the presence of water in the interior cavity 218 and/or fluid reservoir 204 (e.g., via a dashboard indicator inside a vehicle or another suitable user interface) . In other embodiments, the WIF sensor 246 is configured to control operation of the drain valve 242 when water is detected in the interior cavity and/or fluid reservoir 204 (e.g., to selectively open the drain valve 242 when water is detected, to drain the water from the interior cavity 218 and/or the fluid reservoir 204) .

As shown in FIG. 2, the filter assembly 300 is coupled to the tank shell 202 and extends into the interior cavity 218. The filter assembly 300 includes a filter element 302, a filter head 304 coupled to the filter element 302, a locknut 306, and a fuel pump 308.

As shown in FIG. 7, the filter head 304 and the locknut 306 are structured to engage the tank shell 202 to couple the filter assembly 300 to the tank shell 202. In at least one embodiment, the filter head 304 is structured to sealingly engage the tank shell 202 and to fluidly couple the filter assembly 300 to other parts of the filtration system 100. As shown in FIG. 7, the filter head 304 comprises a disc-shaped member having an outer diameter that is approximately the same as an outer diameter of the cylindrical protrusion 220. The disc-shaped member has a substantially planar lower surface that is structured to engage a sealing element 250 (e.g., O-ring, gasket, etc. ) of the fuel tank assembly 200. In the embodiment of FIG. 7, the sealing element 250 is disposed at least partially within an axially facing groove 252 extending along the upper end of the cylindrical protrusion 220.

In the embodiment of FIG. 7, the filter head 304 is pressed against the upper end of the cylindrical protrusion 220 by the locknut 306 (e.g., locking ring, collar, etc. ) . The locknut 306 engages an upper filter head surface 310 of the filter head 304 and extends around an outer radial edge of the filter head 304. The locknut 306 includes an outer wall that extends axially past the filter head 304 and away from the filter head 304 toward the cylindrical protrusion 220. As shown in FIG. 7, the locknut 306 is rotatable with respect to the filter head 304 so as to threadably engage the outer wall with the cylindrical protrusion 220.

In some embodiments, the filter head 304 includes at least one connection port that can be used to connect the filter assembly 300 to other parts of the filtration system 100. For example, the filter head 304 of FIG. 7 includes an outlet port 314 structured to direct clean fuel away from the filter assembly 300. The filter head 304 also includes a through-hole opening 316 used as a pass-through for the electrical connections for the fuel pump 308.

In at least one embodiment, a venting element for the fuel tank assembly 200 is integrated into the filter assembly 300. For example, as shown in FIG. 7, the filter head 304 may include a vent opening 318 extending therethrough, which can be used to vent any air trapped within the interior cavity 218 and/or the fluid reservoir 204 (e.g., due to the fluid coupling between the fluid reservoir 204 and the interior cavity 218) . The vent opening 318 can also facilitate venting of the interior cavity 218 after replacing the filter element 302 (e.g., to introduce fuel from the fluid reservoir 204 into the interior cavity 218.

Returning to FIG. 2, the filter element 302 is coupled to the filter head 304 and includes a media block 320, a first end plate 322 engaged with and coupled to a first axial end 323 of the media block 320, and a second end plate 324 engaged with and coupled to a second axial end 325 of the media block 320.

The media block 320 extends between the first end plate 322 and the second end plate 324 and is sealingly engaged with the first end plate 322 and the second end plate 324. In the embodiment of FIG. 2, the media block 320 includes a media pack 326 and a coalescer 328 nested within the media pack 326. The media pack 326 may comprise a formed (e.g., pleated, corrugated, etc. ) filter media. As shown in FIG. 2, the media pack 326 is arranged as a cylindrical tube that circumscribes a central cavity 330 having a central axis 332.

In some embodiments, each of the media pack 326 and the coalescer 328 include filter media structured to filter particulate matter and/or water from fuel flowing therethrough so as to produce filtered fluid (e.g., clean fluid) . The filter media may include porous material having a predetermined pore size. The filter media may include a paper-based filter media, a fiber-based filter media, or the like. In an embodiment, the coalescer 328 is a fuel-water separator containing coalescing pleated media and stripping media to achieve optimal water/particle removal and engine protection. In another embodiment, the media pack 326 also includes coalescing pleated media and/or stripping media. At least one of the media pack 326 and the coalescer 328 may also include a hydrophobic screen, which can improve water separation performance.

In the example embodiment of FIG. 2, the media pack 326 and the coalescer 328 are each arranged as an outside-in flow filter having an outer dirty side and an inner clean side. Fluid to be filtered passes from the dirty side of the filter element 302, in a radial direction through the media pack 326 and the coalescer 328, to the clean side of the filter element 302 (e.g., the central cavity 330) . In at least one embodiment, the media pack 326 and the coalescer 328 are affixed to one another by at least one end plate (e.g., the first end plate 322 and/or the second end plate 324) to form a unitary body. As shown in FIG. 2, the media pack 326 and the coalescer 328 are also affixed to one another by a second end plate 324. In one embodiment, the filter element 302 also includes a perforated centertube 334 extending axially between the first end plate 322 and the second end plate 324 to improve the strength of the filter element 302 under differential pressure across the filter element 302.

As shown in FIG. 7, the first end plate 322 is structured to engage the filter shell 206 to prevent over-insertion of the filter element 302 into the filter shell 206. In one embodiment, the first end plate 322 includes a first end plate base 336 coupled to the first axial end 323 of the media block 320, and a first end plate ledge 338 extending radially away from the first end plate base 336. An upper surface 337 of the first end plate base 336 may be substantially flush with an upper surface 339 of the first end plate ledge 338. In some embodiments, the first end plate ledge 338 is configured to engage a ledge of the filter shell 206 (e.g., the upper filter shell ledge 238) along an axial direction (e.g., along a direction parallel to a central axis of the central cavity) .

In one embodiment, an outer diameter of the first end plate base 336 may be sized to accommodate the radial gap between the media pack 326 and the second filter shell wall 230 which, beneficially, can facilitate alignment between the filter element 302 and the filter shell 206 during installation. As shown in FIG. 7, a thickness 340 of the first end plate base 336, within the gap between the media pack 326 and the filter shell 206, is greater than a thickness 342 of the first end plate ledge 338. The change in thickness between the first end plate base 336 and the first end plate ledge 338 allows insertion of at least a portion of the first end plate base 336 into the radial space between the filter element 302 and the filter shell 206 to facilitate alignment between the filter element 302 and the filter shell 206.

As shown in FIG. 7, the first end plate 322 also includes a through-hole opening, shown as first end plate opening 321 that is coaxial with the central axis 332 of the central cavity 330. In one embodiment, the first end plate opening 321 is sized to receive at least a portion of the fuel pump 308 therein. In other embodiments, the first end plate opening 321 is structured to receive a standpipe or another conduit to fluidly connect the clean side of the filter element 302 to other parts of the filtration system 100. The filter element 302 may also include sealing members (e.g., gaskets, O-rings, etc. ) disposed at the first end plate opening 321 to prevent fluid leakage across the opening. For example, the first end plate opening 321 may include at least one first end plate sealing member that may be configured to engage the fuel pump 308 along a radial direction (e.g., in a radial sealing arrangement) .

The second end plate 324 is structured to sealingly engage the filter shell 206 to prevent fluid bypass between the clean and dirty sides of the filter element 302. As shown in FIG. 8, the second end plate 324 extends across the second axial end 325 of the media pack 326 and extends at least partially across the second axial end 325. In some embodiments, the second end plate 324 includes a through-hole opening, shown as second end plate opening 327 that is fluidly coupled to the central cavity of the filter element to allow separated water to drain to a region of the interior cavity 218 (e.g., the water collection bowl) below the second end plate 324.

As shown in FIG. 8, the second end plate 324 also includes a sealing groove 344 facing radially away from the central axis 332 of the central cavity 330. As shown in FIG. 8, the filter element 302 further includes a second end plate sealing element 346 disposed in the sealing groove 344 and structured to form a radial seal with the filter shell 206.

As described above with reference to FIG. 5, the filter element 302 and the filter shell 206 are structured to reduce the force required to fully install the filter element 302 into the filter shell 206. As shown in FIG. 2, the second end plate 324 is sized smaller than the first end plate 322 to allow the second end plate 324 to pass freely through the upper portion of the filter shell during assembly. In particular, the second end plate 324 has a second outer diameter 348 that is less than a first outer diameter 350 of the first end plate 322. It should be appreciated that the relative size of the first end plate 322 and the second end plate 324 may be different in other embodiments.

The fuel pump 308 is structured to draw fuel out of the fluid reservoir 204 and through the filter assembly 300. In one embodiment, the fuel pump 308 is an electric pump powered by energy from an alternator or battery onboard a vehicle. In other embodiments, the fuel pump may be another type of pump or fluid delivery device. In the embodiment of FIG. 2, the fuel pump 308 is integrated with the filter assembly 300 which, advantageously, provides space for other components on the vehicle and reduces the number of conduits needed for routing fuel between different components of the filtration system 100.

As shown in FIG. 2, the fuel pump 308 is coupled to the filter head 304 and extends axially into the central cavity 330 of the filter element 302. In one embodiment, the fuel pump 308 is directly coupled to the filter head 304 via a bolt 356 or another suitable fastener. As shown in FIG. 2, the fuel pump 308 extends axially through the first end plate opening 321 of the first end plate 322 and into a recessed portion 352 of the filter head 304. In at least one embodiment, the filter assembly 300 includes sealing members (e.g., gaskets, O-rings, etc. ) that sealingly engage the first end plate 322 and the filter head 304 to prevent fuel bypass and to prevent leakage through the filter head 304. At least a portion of the fuel pump 308 (e.g., the wire connector 354) extends through the filter head 304 so that a technician may access electrical and/or fluid connections without disconnecting the filter assembly 300 from the tank shell 202.

Referring now to FIG. 9, a cross-sectional view of the fuel tank assembly 200 of FIGS. 1–2 is shown that illustrates the operation of the filtration system 100. As shown in FIG. 9, the fuel pump 308 draws dirty (e.g., unfiltered) fuel 10 from the fluid reservoir 204 through the shell conduit 254 and check valve 257 and into the interior cavity 218 of the filter shell 206. The filter element 302 filters the dirty fuel 10, which passes through the fuel pump 308 (as clean fuel 12) out of the filter assembly 300. The filter element 302 (and particularly the coalescer 328 included therein) also separates water 14 from the dirty fuel 10, which moves toward the bottom of the central cavity 330, through the second end plate 324 and into a water collection bowl 262 beneath the second end plate 324. The water 14 accumulates in the open reservoir 264 until the WIF sensor 246 detects the water and triggers the drain valve 242 to drain the water 14. In other embodiments, an operator or technician may manually actuate the drain valve 242 to drain the water 14 from the water collection bowl 262.

Another embodiment relates to a method of installing the filter assembly 300 and filter element 302 into a fuel tank assembly 200. In at least one embodiment, the method includes attaching a filter element 302 to a filter head 304. A fuel pump 308 may be inserted into the filter element 302, through a first end plate opening 321 of a first end plate 322 of the filter element 302. The filter element 302 may be engaged, at the first end plate opening 321, with the fuel pump 308.

The method further includes aligning the filter element 302 with an interior cavity 218 of a filter shell 206 (e.g., the filter shell 206 of the fuel tank assembly 200) . The second end plate 324 of the filter element 302 is inserted into a first portion of the interior cavity 218 (e.g., the second filter shell wall 230 of FIG. 5) having a greater diameter than the second end plate 324. The filter element 302 is moved along a first distance through the interior cavity 218 while maintaining separation between the second end plate 324 and the walls of the first portion. The first distance may be approximately equal to an axial length of the first portion of the interior cavity 218. The second end plate 324 (e.g., a second end plate sealing element 346 of the second end plate 324) is engaged with a lower portion of the interior cavity 218 (e.g., the fourth filter shell wall 234 as shown in FIG. 5) . In at least one embodiment, the second end plate 324 is sealingly engaged with the walls of the second portion to thereby prevent fluid bypass between the walls and the second end plate 324. The filter assembly 300 may be pressed into the filter shell 206 to engage a first end plate ledge 338 of the first end plate 322 with an upper filter shell ledge 238 of the filter shell 206. In other embodiments, the method may include additional, fewer, and/or different operations.

It should be noted that the term “example” as used herein to describe various embodiments is intended to indicate that such embodiments are possible examples, representations, and/or illustrations of possible embodiments (and such term is not intended to connote that such embodiments are necessarily extraordinary or superlative examples) .

As utilized herein, the term “substantially” and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise numerical ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed (e.g., within plus or minus five percent of a given angle or other value) are considered to be within the scope of the invention as recited in the appended claims.

The terms “coupled, ” “connected, ” and the like as used herein mean the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g., permanent) or moveable (e.g., removable or releasable) . Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another.

It is important to note that the construction and arrangement of the various exemplary embodiments are illustrative only. Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc. ) without materially departing from the novel teachings and advantages of the subject matter described herein. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the embodiments described herein.

While this specification contains many specific implementation details, these should not be construed as limitations on the scope of any embodiment or of what may be claimed, but rather as descriptions of features specific to particular implementations of particular embodiments. Certain features described in this specification in the context of separate implementations can also be implemented in combination in a single implementation. Conversely, various features described in the context of a single implementation can also be implemented in multiple implementations separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a subcombination.

Claims

A fuel tank assembly, comprising:

a tank shell defining a fluid reservoir;

a filter shell defining an interior cavity, the filter shell extending into the fluid reservoir and separating the fluid reservoir from the interior cavity; and

a filter assembly coupled to the tank shell and extending into the interior cavity.
The fuel tank assembly of claim 1, wherein the tank shell includes a cylindrical protrusion extending outwardly from the tank shell, and wherein the filter assembly includes a filter head that is threadably engaged with the cylindrical protrusion.
The fuel tank assembly of claim 1 or 2, further comprising a fuel pump coupled to the filter assembly and extending into the interior cavity.
The fuel tank assembly of any one of claims 1-3, further comprising a drain valve structured to drain fluid from both the tank shell and the interior cavity.
The fuel tank assembly of any one of claims 1-3, further comprising a drain valve coupled to a tank lower wall of the tank shell at a lower end of the interior cavity.
The fuel tank assembly of claim 5, further comprising a water-in-fuel sensor coupled to the tank lower wall of the tank shell, the water-in-fuel sensor configured to detect a presence of water within the interior cavity.
The fuel tank assembly of claim 1, wherein the filter assembly includes a filter head that is coupled to the tank shell, the filter head comprising a vent opening is fluidly coupled to the interior cavity.
The fuel tank assembly of any one of claims 1-7, wherein the filter shell includes a shell conduit extending from the filter shell toward a tank lower wall of the tank shell, the shell conduit fluidly coupling the fluid reservoir to the interior cavity.
The fuel tank assembly of claim 8, further comprising a check valve coupled to the shell conduit, the check valve structured to prevent fluid from leaving the interior cavity.
A fuel tank, comprising:

a tank shell comprising a tank lower wall, a tank upper wall, and at least one tank side wall that together define a fluid reservoir; and

a filter shell integrally formed with at least one of the tank upper wall or the tank lower wall from a single piece of material, the filter shell extending into the fluid reservoir between the tank upper wall and the tank lower wall, the filter shell defining an interior cavity that is accessible from a first tank opening in at least one of the tank upper wall or the tank lower wall.
The fuel tank of claim 10, wherein the filter shell comprises:

an upper axial wall extending from the tank upper wall; and

a lower axial wall extending between the upper axial wall and the tank lower wall, the lower axial wall having a first inner diameter that is less than a second inner diameter of the upper axial wall.
The fuel tank of claim 10, wherein the filter shell comprises a cylindrical extension extending away from the tank upper wall in a perpendicular orientation relative to the tank upper wall.
The fuel tank of claim 12, wherein the first tank opening is disposed in the tank upper wall, the filter shell comprising a first filter shell wall extending radially away from the first tank opening, and a second filter shell wall extending axially away from the first filter shell wall and into the fluid reservoir, the first filter shell wall and the cylindrical extension defining an L-shaped upper ledge.
The fuel tank of claim 10, wherein the filter shell extends between and engages both the tank upper wall and the tank lower wall.
The fuel tank of any one of claims 10-14, wherein the first tank opening is disposed in the tank upper wall, further comprising a second tank opening disposed in the tank lower wall, the first tank opening and the second tank opening fluidly coupled to the interior cavity.
The fuel tank of any one of claims 10-15, the filter shell comprising a lower filter shell ledge extending radially inwardly toward a central axis of the filter shell, the filter shell further comprising an ledge opening disposed on the lower filter shell ledge, the ledge opening fluidly coupling the fluid reservoir with the interior cavity.
A filter element, comprising:

a media block circumscribing a central cavity;

a first end plate coupled to a first axial end of the media block, the first end plate including a first end plate base and a first end plate ledge extending radially away from the first end plate base, the first end plate ledge configured to engage a ledge of a filter shell along an axial direction, the first end plate having a first outer diameter; and

a second end plate coupled to a second axial end of the media block, the second end plate comprising a second end plate sealing element facing radially away from a central axis of the central cavity, the second end plate having a second outer diameter that is less than the first outer diameter of the first end plate.
The filter element of claim 17, wherein a thickness of the first end plate base, between the media block and the first end plate ledge, is greater than a thickness of the first end plate ledge.
The filter element of claim 17 or 18, wherein the second end plate comprises a sealing groove, the sealing groove facing radially away from a central axis of the filter element, the second end plate sealing element disposed at least partially within the sealing groove.
The filter element of any one of claims 17-19, wherein the first end plate further comprises a first end plate opening fluidly coupled to the central cavity, the first end plate opening including at least one first end plate sealing element, wherein the second end plate comprises a second end plate opening that is also fluidly coupled to the central cavity.